AI Coal Maceral Analysis With Noise Image Removal
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Solution Overview
Problem
Conventional maceral analysis in the coke-making process of steelworks relies heavily on manual visual inspection by skilled operators, leading to variability and time-consuming results.
Innovation Solution
A material analysis method using artificial intelligence (AI) models for automated identification and quantification of coal macerals, employing a noise removal AI model and a microstructure classification AI model to distinguish and classify maceral microstructures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual visual inspection by skilled operators is used to classify macerals, then classification accuracy can be maintained, but the process becomes highly time-consuming and shows significant variability among operators
Solution Approach 1:
The patent replaces the manual mechanical inspection process with an automated image processing system using deep learning algorithms. The system captures images of coal macerals and uses neural networks to automatically classify them, eliminating the need for manual visual inspection by operators while maintaining high classification accuracy and significantly reducing analysis time.
Solution Approach 2:
The patent creates digital copies (images) of the maceral samples and uses these copies for automated analysis through deep learning models. Instead of requiring operators to directly examine physical samples, the system processes high-resolution images, allowing multiple analyses simultaneously and eliminating operator-dependent variability.
2Measurement precision
If manual visual inspection is used, then expertise-based classification can be achieved, but the method requires significant operator skill and training
Solution Approach 1:
The patent replaces the human expert's visual inspection capability with an automated deep learning system. The neural network is trained on labeled maceral images to learn classification patterns, thereby encoding expert knowledge into the algorithm. This allows non-expert operators to achieve expert-level classification accuracy without requiring extensive training or experience.
Solution Approach 2:
The system performs self-learning through the deep learning training process, where the model automatically improves its classification capability by learning from labeled training data. The algorithm independently identifies patterns and features without requiring continuous human guidance or adjustment, making the system self-sufficient and easy to operate.
3Stability of the object's composition
If manual point-counting inspection is performed according to KS standard, then standardized classification can be achieved, but the process requires counting at least 500 points which is highly time-consuming
Solution Approach 1:
The patent transitions from one-dimensional point-counting analysis to two-dimensional image-based analysis. Instead of examining individual points sequentially, the system captures and analyzes the entire maceral structure in two dimensions using image processing, allowing simultaneous evaluation of multiple features and significantly increasing analysis throughput while maintaining consistency.
Solution Approach 2:
The system performs preliminary image capture and preprocessing before classification, creating a complete digital record of the sample structure. This preliminary action allows the classification algorithm to simultaneously evaluate all relevant features without sequential point-counting, thereby maintaining standardized classification while dramatically improving productivity.
Data Source
AI summary
In one aspect, the present disclosure relates to a material analysis method which may comprise the steps of: (a) preparing a specimen for structure analysis; (b) training an artificial intelligence model with a training image labelled with a structure aspect of an arbitrary specimen; (c) analyzing a plurality of analysis images not labelled with a structure aspect of a specimen using the trained artificial intelligence model, and removing analysis images classified into preset noise structure aspects; and (d) analyzing, by using the trained artificial intelligence model, the analysis images from which the analysis images classified into the noise structure aspects have been removed, and classifying the analysis images into at least one target structure aspect.


